Customized electronic display and methods of customizing the physical size and/or shape thereof

ABSTRACT

Electronic displays are physically reshaped and/or resized to meet custom specifications for special applications such as avionics, where Commercial Off-The-Shelf (COTS) Liquid Crystal Displays (LCDs) are not typically used. Customization includes cutting the physical display to specified dimensions to fit into a target opening, and resealing the display to preserve proper cell spacing and assure basic functionality. The target opening is typically a control panel or dashboard opening, such as in the cockpit of an airplane. The sealing process may include improving the original seal, and/or providing additional seals. Additional seals may protect sensitive areas against chemical corrosives or contamination, humidity, electrostatic damage, etc., and/or prevent light from passing around the edge of the display image area. Electric continuity may need to be reestablished for electric leads affected during the customization process, and electronic drivers may need to be reattached to the display. Additional modifications and/or enhancements may be made to the display during reshaping and/or resizing. For example, TABs or COGs may be relocated, added, removed, replaced, and/or reoriented; electric circuits may be replaced and/or supplemented with circuits having different functionality; the display medium may be altered and/or replaced; polarizers, filters, and/or films may be added, removed, and/or replaced. The customized display may then be ruggedized by attaching a suitable bezel (face plate) and frame (support hardware) thereto, and the completed, customized display unit may then be installed in the target location and integrated with surrounding hardware and electronics.

FIELD OF THE INVENTION

[0001] The present invention relates generally to electronic displays,and more particularly to the customization of an original display byphysical alteration of the size and/or shape thereof, such that thecustomized display may be used in installations not consideredachievable with the original display.

DEFINITIONS

[0002] In this application, COTS is used as an acronym for “CommercialOff-The-Shelf”; FPD is used as an acronym for “Flat-Panel Display”; LCDis used as an acronym for “Liquid Crystal Display”; PDLC is used as anacronym for “Polymer-Dispersed Liquid Crystal”, AMLCD is used as anacronym for “Active Matrix Liquid Crystal Display”; TAB is used as anacronym for “Tape-Automated-Bonding”; COG is used as an acronym for“Chip-On-Glass”; UV is used as an acronym for “ultraviolet”, VLSI isused as an acronym for “Very Large Scale Integration”, and HDTV is usedas an acronym for “High-Definition Television”. All of these terms arewell-known in the art.

BACKGROUND

[0003] Electronic displays are commonly used to portray data in theforms of visual text and/or other images, so the data may be interpretedand/or acted upon. Typically, the operator of equipment associated withthe display will control the equipment based in part on theinterpretation of the data displayed. A simple example is an airplanepilot who views a control panel display representing surrounding airtraffic, and who then controls the airplane to avoid the traffic.

[0004] The displays and their associated bezels (face plates) and frames(interfacing and supporting hardware) are typically built to demandingspecifications for durability, reliability, and operating life, due toindustry requirements, and the resulting displays have relativelycomplex electrical, chemical, optical, and physical characteristics.Each particular application, for example, may require specificperformance characteristics from the display, such as the ability toaccommodate or withstand varying conditions of temperature, humidity,radiation, ambient light, shock, vibration, impact, chemicals, saltspray, water and fluid condensation, immersion, or other environmental,electrical, physical, and/or other conditions. Due to the high costsassociated with such varying and demanding specifications, for anyparticular application it is thus economically necessary formanufacturers to produce a common design in high production volume,resulting in COTS displays all having substantially the samecharacteristics for a variety of physical sizes. The sizes vary, but theshapes are generally rectangular until and shapes. The sizes vary, butthe shapes are generally rectangular with an aspect ratio ofapproximately three to four. Common television and computer displaystypically have an aspect ratio of approximately three to four, and aretypically square. HDTV displays typically have an aspect ratio of nineto sixteen.

[0005] For specialized applications where the market may not be largeenough for COTS manufacturers to enter, buyers of displays are requiredto have displays custom-built to fit their size and shape requirements,at a cost up to ten times greater than the cost of a COTS display havingidentical functionality. Alternatively, buyers may choose to incorporatea COTS display into an existing control panel or dashboard opening byphysically altering the size and/or shape of the control panel openingto match the size and/or shape of the COTS display. For mostapplications, however, such modifications cannot be made withoutdisturbing the surrounding instruments, controls, and displays alreadyincorporated into the control panel. Such is the case, for example, onan airplane control panel or other vehicle control panel where largenumbers of instruments and controls are tightly and efficiently packedinto a relatively small area to begin with. And even if the appropriatemodifications could be made, they are typically cost-prohibitive.

[0006] To overcome the above-referenced drawbacks in the prior art, itwould thus be desirable to provide systems and methods for customizing aCOTS display to meet the size and shape requirements of a target controlpanel opening, such that the purchaser of the COTS display may avoidpaying the extra costs associated with having a display custom-builtfrom scratch. Such systems and methods would be advantageous fordisplays that have relatively high tooling costs and relatively lowvolume production associated therewith.

[0007] A particular industry where high-cost custom-built displays areused is the avionics industry, which traditionally used square panelopenings to house mechanical control devices. To retrofit airplanecontrol panels with electronic displays, the industry beganmanufacturing square displays, at a relatively high cost and relativelylow volume compared to the COTS non-square displays which arecommercially used in a wide variety of applications. In fact, thecontrol panels in newly-built airplanes designed to use electronicdisplays, are still often made with square panel openings, despite theCOTS displays being non-square, in order to maintain thewell-established and familiar control panel configurations.

[0008] Since a completed electronic display is delicate and relativelycomplex, most experts in the filed would not expect that customizationof the displays as desired could be accomplished by physically cuttingan original display, changing its size and/or shape, and resealing it,while maintaining its same basic functionality. For example, mostexperts would not expect that a display designed to be a four-inch bysix-inch display with 480 rows by 640 columns of picture elements(pixels) could be cut down to the size of a four-inch by four-inchdisplay with 480 rows by 480 columns, and still operate successfully.

SUMMARY OF THE INVENTION

[0009] Typically, a COTS display comprises two plates, front and back,holding drive electronics on the edges. The plates are typically glassor plastic, and may have polarizers, filters, image enhancement films,and/or viewing angle enhancement films attached thereto. Row and columnorthogonal electric leads distributed throughout an image-generatingmedium are contained between the plates, and a perimeter seal holds theplates together while isolating and protecting the image-generatingmedium from the outside environment. The row and column electric leadstranscend the seal to external leads to which electronic drivers areattached. The electronic drivers are typically VLSI circuits bonded toTAB substrates attached to the display, or directly attached to thedisplay as COG. In some instances the VLSI electronic drivers are madein-situ with the display picture elements.

[0010] The present invention involves systems and methods forcustomizing a COTS display by modifying the physical size and/or shapeof the COTS display to meet the requirements of a target application.This is accomplished by cutting the physical COTS display to reduce itsphysical size and/or shape, and then resealing the display to achievethe desired performance. The basic functionality of the COTS displayremains intact. That is, the customized display will have a new sizeand/or shape, and may have altered electronic drivers, image-generatingmedia, rearranged electronics, additional seals, additional films, etc.,and may actually have enhanced functionality. However, the customizeddisplay will be able to operate in a target application designed tointerface with a display of the same type (e.g., AMLCD) as the original(e.g., COTS) display.

[0011] When the plates are cut, internal electronics might also be cut,often requiring reestablishment of electrical continuity. Similarly, thedisplay electronics may be removed, reattached, or otherwise modified,and filters, polarizers, and/or other films associated with the displayand typically attached externally to the plates may be cut, to conformto the customized display size and/or shape. Thus the opportunity existsto add enhanced functionality to the display. A custom bezel and framemay then be used to house the display, allowing for additionalruggedization of the entire unit.

[0012] To reseal the display, an adhesive is applied along at least thecut edge or edges. A second seal may be added to minimize thepenetration of humidity and other contaminants into the display media(e.g., liquid crystal material) inside the display cell. A third sealserving as a mask may also be applied to prevent back light typicallyused with LCDs from passing through the display around the outer edgesof the display image area.

[0013] Electronic drivers, typically VLSI circuits (bonded to TABsubstrates attached to the display, or attached directly to the displayas COG) may be added, repositioned and/or reattached as needed, and thecircuitry on the display plates may be altered to make electricalconnection to the new VLSI circuits. Filters, films, polarizers, etc.,may then be cut and/or installed as desired, and additional componentssuch as heaters, optical elements, infrared filters, touch panels,transducers, etc., may be added to alter and/or enhance durability orfunctionality of the display.

[0014] Finally, the reshaped and/or resized, and/or otherwise altereddisplay is placed in a custom bezel and frame with appropriateruggedization characteristics. The bezel and frame are designed toaccommodate the newly sized and/or shaped display in a suitable manner,and to allow for proper mechanical and electrical attachment to thetarget location, such as an avionics box or display panel. The bezel andframe also are configured for installation such that appropriatelighting, optical elements, transducers, heaters, infrared filters,touch panels, etc., associated with the target application operateproperly. The frame thus protects the display and interfaces the displaywith the target location, such as an avionics box or display panel.Suitable adhesives, sealants, conformal coatings, potting compounds,electrical and thermal conductors, screws, clamps, rivets, connectors,gaskets, etc., may be used as necessary or desired to further ruggedizethe unit and install it into its target location. Ruggedization may berequired, for example, before installing the customized unit intoenvironments of vehicles, ships, submersibles, missiles, aircraft,spacecraft, portable equipment, etc., which tend to be more restrictiveand severe than the environments for which COTS displays are designed.Similarly, simulators for situations such as those described above mayalso require ruggedization of the customized unit.

[0015] One aspect of the present invention thus involves customizing anelectronic display by cutting the display along desired dimensionsresulting in a target display portion and an excess display portion, andapplying a first seal between the plates along an exposed edge of thetarget display portion, said first seal creating a barrier to preventthe image-generating medium from escaping out of the area between theplates, wherein the basic functionality of the display remains intact. Asecond seal and/or a third seal may be added.

[0016] Another aspect involves customizing an electronic display bycutting the display along desired dimensions resulting in a targetdisplay portion and an excess display portion, applying a first sealalong an exposed edge of the target display portion between the plates,applying a second seal over the first seal, and applying a third sealover the second seal, wherein the basic functionality of the displayremains intact.

[0017] Another aspect of the present invention involves creating acustomized electronic display comprising a substantially flat frontplate having an upper surface and a lower surface, a substantially flatback plate having an upper surface and a lower surface, said back platepositioned behind said front plate and substantially parallel thereto, aperimeter seal positioned between said plates and forming an enclosedcell area defined by the lower surface of the front plate, the uppersurface of the back plate, and the perimeter seal, an image-generatingmedium contained within said cell area, electrical conductorsdistributed throughout said image-generating medium, a substantiallyflat first polarizer attached to the upper surface of said front plate,said first polarizer having a perimeter, a second seal positioned overthe perimeter seal, and a first silicone bead positioned over theperimeter of the first polarizer. A third seal may be added.

[0018] Systems and methods are thus described for customizing anoriginal (e.g. COTS AMLCD) display to meet the size and/or shaperequirements of a target location. Other objects and advantages of thepresent invention will be apparent from the detailed description whichfollows, when read in conjunction with the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1A is a plan view of a typical COTS AMLCD.

[0020]FIG. 1B is a cross-sectional view of FIG. 1A, along line 1B-1B,with the column TABs removed from the cross-section for purposes ofclarity.

[0021]FIG. 2A is a plan view of a customized display made from the COTSAMLCD shown in FIG. 1A, by cutting along line 2-2 in FIG. 1, and thenresealing.

[0022]FIG. 2B is a cross-sectional view, along line 2B-2B, of thecustomized display shown in FIG. 2A, with the column TABs removed fromthe cross-section for purposes of clarity.

[0023]FIG. 3 is a plan view of a customized display, showing additionalspecial cuts that might be required as part of the customization.

[0024]FIG. 4A is a partial cross-sectional view of a customized displayhaving staggered cuts on the opposing plates, showing first and secondseal layers.

[0025]FIG. 4B is a partial cross-sectional view of a customized displayhaving aligned cuts on the opposing plates, showing a third seal layer.

[0026]FIG. 4C is a partial cross-sectional view of a customized displayhaving an extended lower plate for use to attach electronic drivers orjumper wires.

DETAILED DESCRIPTION OF THE INVENTION

[0027]FIGS. 1A and 1B show a typical rectangular, non-square COTS AMLCD10, before resizing and/or reshaping, but after disassembly from itsoriginal bezel, frame, and other associated hardware and electronics.The external components associated with the display 10 other than thecircuit boards 15 and the components bonded or attached to the displayplates 20 f and 20 b, have been removed for clarity. Such externalcomponents would preferably be removed prior to performing thecustomization of the display 10 as described herein.

[0028] The display 10 comprises a front plate 20 f and a back plate 20b, each preferably made of glass or plastic. The plates 20 are heldtogether by a perimeter seal 25 such as a UV curing urethane as is knownin the art, and are also typically further secured within a bezel (notshown) which is in turn secured to a frame or other hardware (not shown)for attachment to the target location. Polarizing films 30 f and 30 b,filters (not shown), image enhancement films (not shown), retardationfilms (not shown), viewing angle enhancement films (not shown), and/orother films may exist on the front and/or back outer surfaces of theplates 20. The original display image area 40 defined by themanufacturer of the COTS AMLCD is indicated by dashed perimeter line 45.(Dashed line 50 represents the desired right edge of the display imagearea 40 after customization, as will be described shortly). Alight-blocking mask (not shown) is typically placed between plates 20and covers a perimeter area form the outer edge of the display imagearea 40, and extending outwardly to a sufficient distance to serve itspurpose. Typically, the distance will be up to the edge of the bezel, orto the inner edge 55 of perimeter seal 25 as indicated by arrows 60 inFIG. 1A. Without the mask, light escaping around the edge of the displayimage area 40 might cause distraction to a person viewing the display10.

[0029] Row and column electronic drivers 65 r and 65 c respectively arebonded to TAB substrates 70 r and 70 c respectively, which in turn arebonded to the edges of the plates 20 using electrically-anisotropicadhesives 75 as is known in the art. In avionics, bent TABs (not shown)are often used to save panel area. In addition or alternatively, thedrivers 65 may be attached directly to the plates 20 as COGs. Theelectronic drivers 65 are preferably at least VLSI circuits, havingcorresponding external leads 80 r, 80 c electrically connected throughperimeter seal 25 to the row and column electric leads 85 r, 85 crespectively (see FIG. 2A). For simplicity, only a few leads 80 fromonly one row TAB 70 r and two column TABs 70 c are shown in FIG. 2A, butit is to be understood that each row TAB 70 r and each column TAB 70 cmay have dozens or even hundreds of individual leads 80 as is known inthe art. The row and column electric leads 85 are distributed throughoutan image-generating medium such as liquid crystal material (normallytransparent) contained between the plates 20, as seen in FIG. 2A. Theperimeter seal 25, in addition to holding the plates 20 together,isolates and protects the image-generating medium from the outsideenvironment. The TABs 70 are bonded or soldered to circuit boards 15,and are electrically connected to external sources via connections 90 tocircuit boards 15, and as is well known in the art. COGs (not shown) maybe electrically connected to the edges of the display plates 20 whichare connected electrically via ribbon cables to external sources, as isknown in the art. Again, for simplicity only a few connections 90 areshown in FIG. 2A, but it is to be understood that they may be providedas desired or needed.

[0030] To customize the COTS AMLCD 10 of FIG. 1A, an example will bedescribed wherein the display 10 (and circuit boards 15) are cut alongline 2-2 in FIG. 1 to reshape the display 10 to fit into a square targetpanel opening, such as that of an airplane control panel. The resultingcustomized display 10′ is shown in FIGS. 2A and 2B. The customization ofa COTS display 10 may be done in varying degrees, as necessary ordesired, and the examples provided herein are not to be viewed assetting forth required techniques unless specifically so stated.

[0031] The COTS display 10 is preferably first mounted into a fixture(not shown) to stabilize the display 10 in preparation for cutting. Thefixture may also be used to maintain cell thickness (the distancebetween the plates 20) and desired dimensions. Part or all of thefixture may be the VPI FAST-24 model glass-cutting machine made by VillaPrecision International, Phoenix Ariz.

[0032] The display 10 is then cut to its desired shape along the desireddimensions, which in our example is a square. The cut or cuts may beperformed in a single step, by laser cutting, sawing, grinding, etc., orin multiple steps wherein the first step is a tracing or preparatorystep. For example, the desired dimensions might first be scribed,etched, traced, etc., and the display 10 may then be broken along thescribe dimensions. Any method sufficient to ensure a substantiallysmooth cut is acceptable. Scribing with a precision glass-cuttingmachine with vacuum-holding and optical alignment capability has beenshown to be sufficient. AMLCDs are typically made with a borosilicatehard glass and approximately 60 pounds of pressure has been shown to besufficient for scribing the glass. The scribe wheel is preferably madeof diamond or is of a hard carbide type. A small wheel (e.g., 1 mm to 4mm in diameter) with a sharp angle (e.g., approximately 100 degrees) hasbeen shown to be sufficient, at a nominal cutting speed. Each plate 20should be scribed separately. The optical alignment feature of themachine is helpful to ensure that the corresponding scribe lines onopposing plates 20 f and 20 b are coincident or displaced as desired.Alignment marks placed on COTS displays by manufacturers may be used foralignment in the glass-cutting machine.

[0033] Circuit boards 15 may also be cut by techniques known in the art,as indicated by cut-line 2-2, as can TABs 70. However, if a dimensionline calls for cutting through an electronic driver 65, the driver mayneed to be relocated and/or replaced. If polarizers 30 or other filmsare present, it is possible to cut them simultaneously while cutting theplates 20, but it is preferable that they are scored first to create atarget polarizer portion for further use in the customization process,and an excess polarizer portion that may be discarded. The excesspolarizer portions are then removed prior to cutting the plates 20.Doing so allows unobstructed access to the plates 20 for cutting theplates 20. After scoring the films, simple peeling away of the unwantedportions has been shown to be sufficient.

[0034] Thus, the specific dimensions of the score lines to remove thefilms should be selected to substantially correspond to the targetcutting dimensions, but be offset radially inward a slight amount. Thegoal is to allow the original films to remain intact over the targetdisplay image area 40′ while still providing unobstructed access to theplates 20 for cutting the plates 20. For example, in FIG. 1A, the targetdisplay image area 40′ is defined by the square A-B-C-D, and the targetcutting line for the plates 20 is shown as line 2-2. The target scoreline for the polarizers 30 and other films present might be line 95.After scoring, all portions of the films to the right of line 95 will bepeeled away. Similar procedures would be used for each display plate 20f, 20 b. That will leave sufficient leeway 100 between the targetcutting line 2-2 for the plates 20, and the newly-exposed edge (definedby line 95) of the polarizers 30 and films. Additionally, the remainingportions of the original polarizers 30 and films will still cover thetarget display image area 40′.

[0035] Immediately, or soon after the display 10 is cut (either bydirect cutting or by scribing and breaking, for example), the display 10is oriented to prevent the liquid crystal material or otherimage-generating medium from escaping due to any newly-exposed unsealededges. Precision glass-breaking machines are available from VillaPrecision International, Phoenix Ariz. Manual breaking, after scribing,by one skilled in the art, merely using hands and fingers, has beenfound to be sufficient. After breaking, a simple manual re-orientationof the display 10′ has been shown to be sufficiently timely. Typically,the image-generating medium is not viscous enough to escape. The excessdisplay portion (105 in FIG. 1A), may be discarded, while the targetdisplay portion (110 in FIG. 1A) is retained for further customization.

[0036] The newly-exposed plate edges are then cleaned and wiped dry ofany excess liquid crystal material using, for example, a dry cottonswab. Care should be taken to not use fluids, as fluids mightcontaminate the liquid crystal material. Liquid crystal material is thendrained or wicked out of the cell to allow for a replacement seal line115 to be placed along the then newly-exposed and newly-unsealed plateedges. The replacement seal 115 is installed by applying an adhesivealong the cut edge and preferably in between the plates 20 to reseal thedisplay 10′. The adhesive is preferably chosen to have proper mechanicalproperties to preserve the cell spacing. For example, precisionmicro-spheres may be mixed into the adhesive to ensure spacing. Theadhesive should also have a proper viscosity to allow it to flowinwardly sufficiently to fill any void in the cell between the plates 20and the liquid crystal material. Low-viscosity UV curing urethane of themethacrylate family have been shown to have the desired characteristics.A wetting and/or thinning agent may be used as needed. In addition,these urethanes interface with the liquid crystal material withoutadverse effects, as is well-known in the field of PDLCs. Curing time ofapproximately five minutes has been shown to be sufficient.

[0037] The adhesive and display 10′ may need to be outgased to removeany trapped gases and voids, as the adhesive is being cured. Both theoutgassing and the curing may be accomplished by techniques well-knownin the art. After curing, a second seal 120 is preferably added, thenoutgased and cured as necessary. A UV curing lamp(s) and/or heater(s)may be mounted in a vacuum chamber for ease in outgassing and curing.The second seal 120 is preferably silicone, and is applied to minimizethe penetration of humidity and contaminants into the liquid crystalmaterial inside the cell. The silicone seal 120 is preferably thermallyset, as is known in the art. The silicone seal 120 may have black ink,dye, or pigment added thereto to produce a substantially black-coloredsilicone, and may be applied up to the outer perimeter of the targetdisplay image area 40′, to prevent back light from passing through thedisplay 10′ around the outer edges of the target display image area 40′.

[0038] Alternatively, an optional mask or third seal 125 may be added tothe newly-exposed plate edges over the silicone seal 120, and applied upto the outer perimeter of the target display image area 40′. The mask125 is shown partially broken away in FIG. 2A. It should be dark(preferably black), and may be tape, ink, sealant, adhesive, plastic, orany other suitable material. At least one of the dark silicone seal 120,or the optional mask 125, are preferred, to replace any of the originalmask (not shown) removed during the customization process. Additionally,the mask 125 may be placed around the entire perimeter of the cell,substantially overlaying the original perimeter seal 25 and originalmask.

[0039] If internal electronics 85 are cut, electrical continuity mayneed to be reestablished as will be described shortly. Similarly, newVLSI circuits 65 may be needed, or the dimension lines may intersect aTAB 70 or COG location (see FIG. 3 for example), and therefore the TABs70 or COGs would be removed and reattached with the same or new VLSIcircuits 65 by techniques used in the industry for repairing displays.The configuration of the TABs 70 and/or COGs may be changed toaccommodate size and packaging requirements. The circuitry on thedisplay plates 20 may be altered to make electrical connection to thenew VLSI circuits. The COG circuits may be changed to TABs 70, and viceversa. The TAB substrate 70 itself may be changed to bent tabs, forexample, to accommodate new packaging requirements.

[0040] If it is desired to replace the liquid crystal material, thematerial may be extracted and replaced with another image-generatingmedium, to enhance or alter performance. If the extraction is to be donefirst, then only a single break in the seal 25 is needed to drain orsuck out the original material. However, two breaks in the seal 25 maybe used—one to apply pressure and the other to apply suction forextraction of the material. With two breaks, the new image-generatingmedium may be pumped or fed into the pressure end concurrently with thesuction on the other end, thus allowing the new image-generating mediumto displace the old material in a single process. Other techniques areknown in the industry for refilling the cell.

[0041] Thus, additional modifications and/or enhancements that may bemade to the display during reshaping and/or resizing include relocating,adding, and/or removing, TABs 70 or COGs; replacing electric circuitsand/or supplementing with circuits having different functionality;altering and/or replacing the display medium; and/or adding, removing,and/or replacing polarizers, filters, and/or films.

[0042] Turning now to FIG. 3, a display 10′ with additional special cuts130, 135, and 140, for a custom avionics application is shown. In thisexample, the corners 150 and 155 are to be removed to allow for theprotrusion of screws and other mechanical and electrical objects fromthe target control panel, and one edge 160 is to be trimmed as indicatedby cut-line 140. Additionally, circular cuts 145 f and 145 b arerequired for protrusion of a shaft or other object such as a mechanicalindicator. The circuit boards 15, seals 25, and most of the TABs 70 havebeen removed for clarity of the drawing. In this example, one of thedimension lines 140 requires a cut through the present location of a TAB70, such that the TAB 70 may need to be removed and reattached, eitherbefore or after cutting.

[0043] The row and/or column leads (85 r and 85 c respectively) areexposed at points 165 by a staggered cut of the plates 20, and may becleaned and prepared as is known in the art, prior to being connected toa TAB 70 or COG. The techniques previously described may be used for thespecial cuts 130, 135, 140, and 145. However, as exemplified by thecircular cuts 145, this example shows a situation wherein the electricalcontinuity of the row and/or column leads (85 r and 85 c respectively)will need to be reestablished.

[0044] The proper electrical connections may be reestablished using ajumper wire which reconnects the broken leads by traversing a pathoutside of the display image area 40′. For example, one such path isalong the exposed portion of a plate 20 from one end of the plate 20 tothe other (see 170 in FIG. 3). Another such path may be through thecircular cutouts (see 145 in FIG. 3), where there may be an exposedsurface portion 175 on the back plate 20 b due to staggered cutting(e.g., the circular cutout 145 f on the front plate 20 f may have alarger diameter than the circular cutout 145 b on the back plate 20 b,as seen in FIG. 3). Alternatively, the conductive paths may be mountedon or integrated within the under surface of the mechanical indicator tobe placed within the circular cutouts 145. This may be accomplishedusing, e.g., a wire, a polyimide tape circuit with anisotropicconductive adhesive, or a circuit board with appropriate electricalconnectors.

[0045] For desired dimensions such as the circular cutout, some amountof the image-generating medium may escape at virtually any orientationof the display 10′ due to gravity. Keeping the plates 20 substantiallyflat, however, should minimize such escape, due to surface tensionbetween the image-generating medium and the plates 20, as well as due tothe low viscosity of the image-generating medium. Any escaped material,however, may be replaced using techniques described herein and/or knownin the art. The exposed edges of the plates 20 due to the circularcutout areas 145 should be sealed using the techniques described herein.

[0046] Turning now to FIGS. 4A, 4B, and 4C, various sealing techniqueswill be described in more detail. Each of these drawings shows a partialcross-section of a customized display 10′, from a similar perspective asin FIGS. 1B and 2B, and like FIGS. 1B and 2B, the column TABs 70 c havebeen removed for clarity.

[0047] The display 10′ may be cut to various pre-sealing arrangements,some of which are shown in FIGS. 4A, 4B, and 4C. The staggered cut,shown in FIG. 4A, provides an extra exposed surface 180 on the backplate 20 b to support the second seal 120, and the second seal 120 willgenerally be stronger as compared to the second seal 120 on an evenlycut set of plates 20 as shown in FIG. 4B. Though neither the second seal120 nor the third seal (the light mask 125) are required, they are bothpreferred.

[0048] The first seal 115 is an adhesive and serves the purpose ofbarricading the image-generating medium from leaking out, as well asmechanically holding the plates 20 together at the proper spacing. Byway of example, the cell gap (space between the plates 20) for AMLCDs istypically 6 micrometers with tolerances of 0.1 micrometers. Glass beads,or suitable objects, may be added to the seal material to aid inpreserving the minimum cell thickness. The adhesive must be chemicallycompatible with the image-generating medium. The compatibility, reactingand mixing of urethanes, epoxies, and water emulsions, with liquidcrystal materials, have been studied extensively in the field of PDLCdisplays. The UV-curing adhesives used to repair automobile glass crackswould be suitable here as the environmental conditions may be similar.

[0049] The second seal is a silicone adhesive and serves the purpose ofa humidity and moisture barrier. A family of silicone encapsulants andadhesives has been developed for the electronics industry to preventhumidity and moisture from attacking electronic parts. As used with themethods described herein, the use of silicone is designed primarily tokeep water molecules away from the liquid crystal material, polarizers,and display electronics. Silicones such as Sylgard brand by Dow ComingCorporation, part numbers 527 and 184, may be used. The humidity andmoisture protecting properties of silicone are well-known in theelectronics packaging industry.

[0050] As a further ruggedizing measure, a silicone seal or bead 185(similar to the second seal 120) may be applied along all cut edges, orall edges, of the polarizers 30 and other films, as seen in FIGS. 4A,4B, and 4C. For example, when submitted to avionics temperature/humiditytesting, the polarizers 30 deteriorated at the edges. These seals 185would further protect the polarizers 30 from such damage. In fact, toruggedize a COTS display 10 for avionics use, all permeable seam linesand areas sensitive to moisture may be covered with silicone seals. Inparticular, the polarizer edges, the liquid crystal cell seal 25,plastic electronics packages, and any exposed conductors or metalelectrodes may need to be covered. The silicone has the effect ofoccupying all chemically active sites and cross-linking to inhibit watermolecules from accumulating in the silicone and at the silicone surfaceinterface being protected. Additionally, silicone is used to suppresscorona discharge and electrostatic detrimental effect on, around, andnear conductors.

[0051] These additional silicone seals may be applied at any time duringthe process, but it is preferred that they are applied after the COTSdisplay 10 is cut and the first seal 115 has been reapplied. It shouldbe done then because silicone chemically attaches to most surfaces andis not easily removed by conventional chemicals or cleaning agents or bysurface cleaning techniques. Also, once cured, the silicone is notreadily bonded to by other materials. This includes the body of thesilicone, as well as any surface the silicone wetted, even after removalby conventional techniques. Because of the unique properties of siliconeadhesives and sealants, they should be used sparingly and appropriatelyby a person skilled in the art of sealants or silicone use. Conformalcoatings, such as polyimide, may also be used to cover the exposedelectric leads and provide additional protection thereto.

[0052] A third seal or mask 125 may also be used to prevent back lightfrom passing through the display 10′ around the outer edges of thetarget display image area 40′. Typically, a COTS display 10 has a blackmask in the plane of the image or image-generating medium. The thirdseal 125 should be applied to the top and bottom of the plates 20, up tothe edge of the target display image area 40′ (best seen in FIG. 2A), totrap the light and prevent its escape due to parallax between theplates. Opaque layers in varying degrees of opacity may be used.Alternatively or in addition, black absorbing dyes or pigments may beincluded in the first seal 115 and/or second seal 120.

[0053] Other seals may be added to further enhance the sealing,ruggedization and performance of the completed display unit. Forexample, a thermal conductive perimeter seal may be added to conductheat to or from the display 10′. An additional adhesive layer, such aspolysulfide, may be used to bond the display glass cell to a metalframe. Conformal coatings such as polyimide may be used to ruggedizevarious parts.

[0054]FIG. 4C shows a cutting arrangement resulting in an extendedbottom plate area 190, which may be used to attach TABs 70 or COGs orjumper wires as desired.

[0055] The basic fumctionality of the original display remains intact.That is, the customized display may have a new size and/or shape, andmay have altered electronic drivers, image-generating medium, rearrangedelectronics, additional seals, additional films, etc., and may actuallyhave enhanced functionality. However, the customized display will beable to operate in a target application designed to interface with adisplay of the same type as the original display. For example, a COTSAMLCD, having gone through a customization process as described herein,will be able to function in an avionics application designed tointerface with an AMLCD. The customized display would respondappropriately to electrical signals designed to be input to the COTSdisplay. Pixels on the customized display would continue to operate asthey would in connection with the COTS display. The speed of response,contrast ratio, gray shades, etc., of the customized display wouldoperate as they would in connection with the COTS display. The ultimateimage (text, graphics, pictures, etc.) would thus appear appropriatelyon the display image area of the customized display.

[0056] While certain embodiments are illustrated in the drawings and aredescribed herein, including preferred embodiments, it will be apparentto those skilled in the art that the specific embodiments describedherein may be modified without departing from the inventive conceptsdescribed.

[0057] For example, depending upon the specific requirements for aparticular application, various combinations of the customizingtechniques described herein may be applied. The seals 115, 120, 125, and185, may be applied in different combinations, different amounts orratios, and varying sequences, depending on the application. Some of theseals may be omitted or used redundantly as the application may require.

[0058] Additionally, though the examples used herein generally referredto COTS AMLCDs as used in avionics where square displays are used, theconcepts are equally applicable to other types of LCDs or other displaytechnologies, and for other industrial applications including thoserequiring other customized shapes. Furthermore, though the examples usedshow only one set of row TABs and two sets of column TABS, in practicethat may be switched, or there may be two sets of each, and the quantityof each may vary, all as is desired or needed for a specificapplication.

[0059] Accordingly, the invention is not to be restricted except by theclaims which follow.

What is claimed is:
 1. A method of changing the physical shape of anelectronic display, wherein the display comprises a front plate, a backplate, and a perimeter seal spacing apart the plates, and whereinimage-generating medium is contained in an area between the plates andwithin the borders of the perimeter seal, the method comprising thesteps: cutting the display along desired dimensions resulting in atarget display portion and an excess display portion; and applying afirst seal between the plates along an exposed edge of the targetdisplay portion, said first seal creating a barrier to prevent theimage-generating medium from escaping out of the area between theplates; wherein the target display portion retains the basicfunctionality of the display.
 2. The method as in claim 1, furthercomprising the step of applying a second seal along the exposed edge. 3.The method as in claim 2, wherein the second seal comprises silicone. 4.The method as in claim 3, wherein the silicone is substantiallyblack-colored.
 5. The method as in claim 3, wherein the step of cuttingthe display further comprises the steps of cutting the front plate alonga first dimension, and cutting the back plate along a second dimensionresulting in an exposed upper surface portion of the back plate to whichthe second seal attaches.
 6. The method as in claim 3, furthercomprising the step of scoring a polarizer attached to an upper surfaceof the front plate resulting in a target polarizer portion and an excesspolarizer portion.
 7. The method as in claim 6, further comprising thestep of removing the excess polarizer portion from the display beforeperforming the cutting step.
 8. The method as in claim 6, furthercomprising the step of applying a light mask over the second seal and upto an outer perimeter of a target display image area on the targetdisplay portion.
 9. The method as in claim 3, further comprising thestep of applying a light mask over the second seal and up to an outerperimeter of a target display image area on the target display portion.10. The method as in claim 9, further comprising the step of orientingthe target display portion after the cutting step to prevent theimage-generating medium from escaping from between the plates.
 11. Themethod as in claim 3, wherein the display is a COTS AMLCD, and whereinthe target display portion is substantially square.
 12. A method ofchanging the physical shape of an electronic display, wherein thedisplay comprises a front plate and a back plate, the method comprisingthe steps: cutting the display along desired dimensions resulting in atarget display portion and an excess display portion; applying a firstseal along an exposed edge of the target display portion between theplates; applying a second seal over the first seal; and applying a thirdseal over the second seal; wherein the target display portion retainsthe basic functionality of the display.
 13. The method as in claim 12,wherein the second seal comprises silicone.
 14. The method as in claim13, wherein the display further comprises a perimeter seal spacing apartthe plates, and further comprising the step of applying the second sealover the perimeter seal.
 15. The method as in claim 13, wherein thetarget display portion farther comprises a polarizer attached to anupper surface of the front plate, and further comprising the step ofapplying a silicone bead over an edge of the polarizer.
 16. The methodas in claim 15, wherein the third seal extends onto the upper surface ofthe front plate and up to an edge of a target display image area. 17.The method as in claim 16, wherein the display is a COTS LCD.
 18. Themethod as in claim 17, wherein the target display portion issubstantially square.
 19. A method of changing the physical shape of aCOTS LCD comprising the steps: cutting the display along desireddimensions resulting in a target display portion and an excess displayportion; applying a first seal along an exposed edge of the targetdisplay portion between the plates; applying a second seal over thefirst seal; replacing an original TAB on the target display portion witha new TAB; and electrically connecting the new TAB to correspondingelectrical leads within the target display portion; wherein the targetdisplay portion retains the basic functionality of the display.
 20. Themethod as in claim 19, wherein the target display portion furthercomprises a polarizer attached to an upper surface of the front plate,and further comprising the step of applying a silicone bead over an edgeof the polarizer.
 21. The method as in claim 20, wherein the targetdisplay portion is substantially square.
 22. An electronic displaycomprising: a substantially flat front plate having an upper surface anda lower surface; a substantially flat back plate having an upper surfaceand a lower surface, said back plate positioned behind said front plateand substantially parallel thereto; a perimeter seal located betweensaid plates and forming an enclosed cell area defined by the lowersurface of the front plate, the upper surface of the back plate, and theperimeter seal; an image-generating medium contained within said cellarea; electrical conductors distributed throughout said image-generatingmedium; a substantially flat first polarizer attached to the uppersurface of said front plate, said first polarizer having a perimeter;and a second seal positioned over the perimeter seal.
 23. The electronicdisplay as in claim 22, further comprising a first silicone beadpositioned over the perimeter of the first polarizer.
 24. The electronicdisplay as in claim 23, further comprising a third seal positioned overthe perimeter seal, the second seal, and the first silicone bead, saidthird seal extending onto the upper surface of the front plate up to anouter edge of a display image area thereon.
 25. The electronic displayas in claim 24, wherein the second seal comprises silicone.
 26. Theelectronic display as in claim 25, wherein the image-generating materialis liquid crystal material.
 27. The electronic display as in claim 23,wherein the second seal comprises silicone, and further comprising asubstantially flat second polarizer attached to the lower surface ofsaid back plate, said second polarizer having a perimeter, and wherein asecond silicone bead is positioned over the perimeter of the secondpolarizer.
 28. The electronic display as in claim 27, further comprisinga third seal positioned over the perimeter seal, the second seal, andthe first and second silicone beads, said third seal extending onto theupper surface of the front plate up to an outer edge of a display imagearea thereon, and extending onto the lower surface of the back plate upto an outer edge of a display image area thereon.
 29. The electronicdisplay as in claim 28, wherein the second seal comprises silicone. 30.The electronic display as in claim 29, wherein the image-generatingmaterial is liquid crystal material.
 31. A method of changing thephysical shape of an electronic display, wherein the display comprises afront plate, a back plate, and a perimeter seal spacing apart theplates, and wherein image-generating medium is contained in an areabetween the plates and within the borders of the perimeter seal, themethod comprising the steps: cutting the display along desireddimensions resulting in a target display portion and an excess displayportion, said desired dimensions not intersecting with the perimeterseal; and applying a first seal between the plates along an exposed edgeof the target display portion; wherein the target display portionretains the basic functionality of the display.
 32. The method as inclaim 31, further comprising the step of applying a second seal alongthe exposed edge, said second seal comprising silicone.
 33. The methodas in claim 32, further comprising the step of applying a light maskover the second seal and up to an outer perimeter of a target displayimage area on the target display portion.